The Ultimate Guide to Exair Gen4 Ionizing Bars: How They Work and Why Your Industry Needs Them

 In industries where static electricity causes operational disruptions, quality issues, or safety concerns, finding an efficient solution is crucial. Enter Exair Gen4 Ionizing Bars—a powerful and reliable tool for static control. Let’s dive into what makes these bars indispensable for modern industrial environments.

What Are Exair Gen4 Ionizing Bars? 

Exair Gen4 Ionizing Bars are anti-static devices that neutralize static electricity on surfaces. Designed for applications where unwanted static can lead to operational inefficiencies, product contamination, or even safety risks, these bars eliminate the charge by emitting ions that neutralize static buildup.

How Do Exair Gen4 Ionizing Bars Work?

The electromagnetically shielded power cable (1) carries the 5kVrms power supply output to each inductively coupled stainless steel emitter point (2) of the Gen4 Ionizing Bar. An integrated ground wire (3) within the power cable creates a discharge path from the emitter points to the bar channel (4). The discharge at each emitter charges the molecules of the gases of the surrounding room air, resulting in a shower of ions that are positively and negatively charged (5). If the material surface has a negative charge, it will attract the positive ions from the Gen4 Ionizing Bar and become balanced or neutralized. If the material surface has a positive charge, it will attract the negative ions from the Gen4 Ionizing Bar to become balanced or neutralized. The voltage potential at each emitter is high enough to ionize the surrounding air without generating a shock when any of the emitters are touched.

Key Features of Exair Gen4 Ionizing Bars

1. Efficient Static Neutralization: Exair Gen4 Ionizing Bars provide fast and effective static elimination, which improves product quality and reduces downtime.

2. Variety of Sizes: Available in different lengths, these bars can be customized for various industrial applications, ensuring the right fit for your needs.

3. Durable Construction: Built with rugged materials, Exair Gen4 Ionizing Bars are designed to withstand harsh industrial environments, offering long-lasting performance.

4. Maintenance-Free Operation: With no moving parts and minimal upkeep required, Exair Gen4 Ionizing Bars are designed for long-term operation without frequent intervention.

5. Safe to Use: These Gen4 Ionizing Bars are armored with rugged metal and electromagnetically shielded cable, ensuring they are safe for use in sensitive environments, including those where electronic components are present.

Industries That Benefit from Exair Gen4 Ionizing Bars

1. Plastics Manufacturing: In plastic molding and film extrusion processes, static can cause dust and debris to cling to surfaces, degrading product quality. Ionizing bars eliminate these issues, improving the finish and clarity of the products.

2. Printing and Packaging: Static can cause materials to stick together or misalign, leading to jams or inaccurate cuts. Exair Gen4 Ionizing Bars ensure smooth handling and reduce waste caused by static-related errors.

3. Textile Industry: In textile production, static buildup can attract dust and dirt, leading to contamination. By neutralizing static, ionizing bars help maintain cleanliness and quality.

4. Electronics Assembly: Static discharge can damage sensitive electronic components. Exair Gen4 Ionizing Bars eliminate the risk of electrostatic discharge (ESD), protecting both components and workers.

Benefits of Using Exair Gen4 Ionizing Bars

1. Enhanced Product Quality: By eliminating static, you reduce the risk of contamination and defects, leading to higher-quality products.

2. Increased Operational Efficiency: With reduced static-related downtime, your production lines can run more smoothly, increasing throughput.

3. Cost Savings: Less downtime, fewer defects, and reduced waste all contribute to cost savings in the long run.

4. Improved Safety: In some cases, static buildup can create unsafe working conditions, especially in environments where flammable materials are used. Exair Gen4 Ionizing Bars help mitigate these risks.

Exair Gen4 Ionizing Bars Specifications

EXAIR Model 7960 or 7961 Gen4 Power Supply (5kV) is required for Gen4 Ionizing Bar operation. 

Certifications:        Gen4 Ionizing Bars and Gen4 Power Supplies are UL Component Recognized to

                                 U.S. and Canadian safety standards, and are CE and RoHS compliant.

Electrical:                For use with 5 kVrms, 5 milliamperes (max.) power supply.

Electrical Hazard:  Gen4 Ionizing Bars are shockless (less than 40 microamperes short circuited).

Do not use near flammable materials or gases.

Materials of Construction

Metal Parts:             Aluminum

Plastic Parts:           UL rated 94 HB

Emitters:                  Stainless Steel

Maximum Ambient Temperature: 165°F (74°C)

Would you like more detailed information or have specific questions about its operation or applications?

Please Click Here to visit our website.

Vivek Engineers #22, 1st Floor, 1st Cross,  Bilekahalli Indl. Area, Adj. IIMB Compound,  Bannerghatta Road, Bangalore - 560 076  Ph : 080 - 31681897, 4170 1145 Email: sales@vivekengineers.net            p.lochan@vivekengineers.net

Stop using liquid coolants! Now time to go for Exair Cold Gun Aircoolant system

 If you're considering switching from liquid coolant to an air-based solution like the Exair Cold Gun, here are some benefits :

Benefits of Using Exair Cold Gun Over Liquid Coolant:

1. Cleaner Operation: No liquid mess or the need for coolant disposal, which can simplify maintenance and reduce environmental impact.
2. Reduced Costs: Eliminates the ongoing costs associated with purchasing, maintaining, and disposing of liquid coolants.
3. Non-Contaminating: Since no liquids are involved, there's no risk of coolant contamination or residues on parts.
4. Consistent Cooling: Provides a steady, reliable stream of cold air, reducing the risk of overheating during machining.
5. Environmentally Friendly: Uses only compressed air, avoiding the environmental concerns related to chemical coolants.
6. Improved Safety: Eliminates the hazards associated with handling and exposure to chemical coolants.

The Exair Cold Gun is a tool used in industrial applications to provide a stream of cold air for cooling purposes. It operates using a compressed air supply, without any moving parts or refrigerants, making it a maintenance-free solution. The cold air produced by the Cold Gun is typically used to cool machining operations, prevent heat buildup in sensitive processes, or provide spot cooling for parts or equipment.

Key Features:

• Compressed Air Powered: The Cold Gun uses compressed air to generate cold air, which makes it efficient and environmentally friendly since it doesn't rely on electricity or refrigerants.

• No Moving Parts: The lack of moving parts means there is minimal wear and tear, resulting in lower maintenance costs and longer operational life.

• Temperature Drop: The tool can lower the temperature of the air by as much as 50°F (28°C) from the ambient temperature.

• Versatile Applications: It's commonly used in CNC machining, metal cutting, and other processes where excessive heat could damage tools or parts.

• Quiet Operation: The Exair Cold Gun is designed to operate quietly, making it suitable for environments where noise reduction is important.

Would you like more detailed information or have specific questions about its operation or applications?

Please Click Here to visit our website.

Vivek Engineers #22, 1st Floor, 1st Cross,  Bilekahalli Indl. Area, Adj. IIMB Compound,  Bannerghatta Road, Bangalore - 560 076  Ph : 080 -  4170 1145 Email: sales@vivekengineers.net            p.lochan@vivekengineers.net

How Exair Air Nozzles Save Money and Compressed Air ?

Industrial air nozzles are widely used in India across various industries for applications such as cooling, drying, blowing off debris, and cleaning. But it is really complicated to find out a proper nozzle based on quality and cost.

Now I am going to explain you how you can save Money and Compressed Air if you select EXAIR Engineered Air Nozzles in India.

One of the worst culprits for inefficient air use is open pipe blow-offs. This would include cheap air guns, drilled holes in pipes, and tubes. These are very inefficient for compressed air and can cost you a lot of money.  I will share a comparison to a 1/8” NPT pipe to an EXAIR Mini Super Air Nozzle.  (Reference below).  As you can see, by just adding the EXAIR nozzle to the end of the pipe, the company was able to save per year.  That is some real savings.

The table above shows the air consumption for typical homemade blow offs. The pages that follow give the air consumption and other data on EXAIR's Air Nozzles and Jets. Consider the following example where a Model 1102 Mini Super Air Nozzle replaces an 1/8" open pipe. The compressed air savings is easy to calculate and proves to be dramatic. Payout for Air Nozzles and Jets, including filter and installation cost is measured in weeks - not years, as is the case for other cost reduction equipment. Based on a 40 hour work week, 52 weeks a year.

Example: 

1. Existing blowoff is 1/8" open pipe at 80 PSIG (5.5 BAR) supply. 

Air consumption, from the table above, is 70 SCFM (1,981 SLPM). 

2. Use a 1/8 FNPT Model 1102 Mini Super Air Nozzle also at 80 PSIG (5.5 BAR) supply. Air consumption, from the image below, is 10 SCFM (283 SLPM). 

3. Compressed air saved = 70 - 10 = 60 SCFM (1,981 - 283 =1,698 SLPM) 

4. For this example, the blow off is continuous. If the duty cycle was 20%, then air saved would be 60 x .2 = 12 SCFM (1,698 x .2 = 340 SLPM).

 5. Most large plants know their cost per 1,000 standard cubic feet of compressed air (10,000 standard liters). If you don't know your actual cost per 1,000 SCF, Rs 29 is a reasonable average to use. 

(Cost per 10,000 standard liters is approximately Rs 10 )

 6. Money saved per hour = SCFM saved x 60 minutes x cost/1,000 SCF

                                            (SLPM saved x 60 min x cost/10,000 SL)

                                          = 60 x 60 x Rs 29 /1,000 

                                         (= 1,698 x 60 x Rs 10 /10,000)

                                             =Rs 104/hour that is =Rs 4160/week and Rs 216,320/year savings for one nozzle.

Now please Let me answer and explain  to a very common question, we are asked during presentation of Exair's Air Nozzles that Why Exair Air nozzles consume less compressed air. 

Well, we will discuss the working principle of Exair Air Nozzles and which is of course the realistic answer.

Air Nozzles use the Coanda effect to amplify compressed airflow up to 25 times or more. As illustrated on top, compressed air (black arrows) is ejected through a series of nozzles on the outer perimeter. As the air travels along the outer wall of the nozzle, surrounding air (blue arrows) is entrained into the stream. The airstream that results is a high volume, high velocity blast of air at minimal consumption. The air is always ejected so it can vent safely, well below OSHA dead end pressure requirements, should the nozzle end be blocked.

For more detailed information or to select the appropriate model for your specific needs, you can visit  official website of Vivek Engineers or contact the Application Engineers.

website www.vivekengineers.net

Padmalochan Nayak

Vivek Engineers #22, 1st Floor, 1st Cross,  Bilekahalli Indl. Area, Adj. IIMB Compound,  Bannerghatta Road, Bangalore - 560 076  Ph : 080 -  4170 1145 Email: sales@vivekengineers.net            p.lochan@vivekengineers.net

Exair Reversible Drum Vac: Efficient Liquid Handling for Industrial Applications

 If  You want to recover Coolant, Hydraulic Oils, Liquid spills, Sludge and Chips, Tramp Oil and Waste Water spills in industrial environments, then we suggest to go for Exair Reversible Drum Vac.

Dear reader, allow me to introduce you to the EXAIR Reversible Drum Vac.

The Exair Reversible Drum Vac is an industrial vacuum system designed to efficiently and quickly convert a standard 55-gallon drum into a powerful liquid vacuum. This tool is particularly useful for applications involving the cleanup of spills, transfer of liquids, and recovery of coolant, oil, or other fluids. Here's an overview of the Exair Reversible Drum Vac, including its features, benefits, and applications:

Overview

The Exair Reversible Drum Vac uses compressed air to create a vacuum within a drum, enabling it to draw in liquids quickly. The unique feature of this system is its reversibility, allowing users to empty the drum just as easily as it is filled.

Key Features

1. Reversible Operation:

   • Fill and Empty: With the turn of a knob, the Reversible Drum Vac can switch from filling the drum to emptying it, providing a versatile solution for fluid handling.

2. Safety and Compliance:

   • No Electricity: Operates on compressed air, eliminating the risk of electrical hazards.
   • Automatic Safety Shutoff: Includes a safety shutoff valve to prevent overfilling.

3. Durability and Construction:

   • Rugged Design: Built to withstand harsh industrial environments with a stainless steel pump for longevity.
   • Maintenance-Free: The system has no moving parts, reducing maintenance needs and increasing reliability.

4. Ease of Use:

   • Quick Setup: Easy to install and operate with minimal setup time.
   • 

Benefits

1. Efficiency:

   • Fast Operation: Capable of filling or emptying a 55-gallon drum in less than two minutes.
   • High Capacity: Ideal for handling large volumes of liquid quickly.

2. Cost-Effective:

   • Energy-Efficient: Uses compressed air efficiently, minimizing air consumption ( 19 SCFM air consumption ).

3. Versatility:

   • Multiple Applications: Suitable for a wide range of liquids, including coolant, oil, water, and sludge.
   • Portable: Can be easily moved between different drums and locations within a facility.

Applications

1. Spill Cleanup:

   • Quick Response: Efficiently handle accidental spills in industrial environments.
   • Recovery: Recover valuable liquids and minimize waste.

2. Liquid Transfer:

   • Coolant Recovery: Transfer coolant from machines to storage or filtration systems.
   • Oil Change: Remove used oil from machinery and equipment for disposal or recycling.

3. General Maintenance:

   • Sump Cleaning: Clean out sumps, tanks, and pits without manual scooping.
   • Machinery Maintenance: Remove liquid waste from machinery during maintenance operations.

Accessories

1. Drum Dolly: Provides mobility for the drum, making it easier to move the system around a facility.
2. Drum Lid: A sealed lid with connections for the vacuum system to ensure a secure and efficient operation.
3. Extension Wands and Hoses: Extend the reach of the system for cleaning hard-to-reach areas.
   
   
   

Conclusion

The Exair Reversible Drum Vac is a robust and versatile solution for industrial liquid handling needs. Its ability to quickly switch between filling and emptying modes, combined with its maintenance-free operation and safety features, make it an essential tool for many industries. For more detailed information or to select the appropriate model for your specific needs, you can visit  official website of Vivek Engineers or contact the Application Engineers.

website www.vivekengineers.net

Vivek Engineers #22, 1st Floor, 1st Cross,  Bilekahalli Indl. Area, Adj. IIMB Compound,  Bannerghatta Road, Bangalore - 560 076  Ph : 080 -  4170 1145 Email: sales@vivekengineers.net            p.lochan@vivekengineers.net

Exair Cabinet Cooler Systems

 Exair(USA)  offers a variety of Cabinet Cooler Systems designed to keep electrical enclosures cool by using compressed air to provide a low-cost and reliable solution. Here are some types of Cabinet Coolers that Exair offers:

1. NEMA 12 Cabinet Coolers: Designed for industrial environments where no liquids or corrosives are present, these coolers provide a reliable and low-cost way to cool electrical enclosures. They are dust-tight and oil-tight. 

1. NEMA 4 Cabinet Coolers: These are used in wet, damp, and/or corrosive environments. They offer the same cooling power as the NEMA 12 models but are more robust against moisture and contaminants. They are dust-tight, oil-tight, splash resistant, indoor/outdoor service incorporate a low pressure relief valve for both the vortex tube and cabinet air exhaust. This valve closes and seals when the cooler is not operating to maintain the integrity of a NEMA 4 enclosure.

   
   
   

2. NEMA 4X Cabinet Coolers: Offer the same protection as NEMA 4, but ideal for corrosive or washdown environments, such as food processing  and corrosive environments. They are made from stainless steel to resist corrosion.

   

3. High Temperature Cabinet Coolers: For ambient temperatures of 125° to 200°F (52° to 93°C) are available. Internal components can withstand high temperatures (like those near furnaces, ovens, etc.).They are suitable for locations with high ambient heat.

   
   
   

4. Non-Hazardous Purge Cabinet Coolers: are ideal for dirty areas where contaminants might normally pass through small holes or conduits. Under normal conditions, the NHP Cabinet Cooler Systems provide a slight positive pressure in the enclosure by passing 1 SCFM (28 SLPM) of air through the cooler, when the solenoid valve is in the closed position. When the thermostat detects high temperature, it energizes the solenoid valve to pass full line pressure and volume of compressed air to the Cabinet Cooler, giving it full cooling capability

   
   
   

5. Hazardous Location Cabinet Coolers: Hazardous Location NEMA 4 (IP66) Cabinet Coolers are engineered and approved for use upon purged electrical enclosures found within classified areas. The areas approved are Class I Div 1, Groups A, B, C and D; Class II Div 1 Groups E, F and G; and Class III. These HazLoc Cabinet Cooler Systems have been tested by UL and meet the stringent UL requirements for these areas. Cabinet Cooler systems are a low cost and reliable way to cool purged electric control panels found within these environments.

   
   
   

6. Cabinet Coolers - ATEX: ATEX Cabinet Cooler Systems are engineered and approved for use upon purged electrical enclosures (not included) found within ATEX zoned areas. The areas approved are Zone 2 and 22.

   
   
   

These coolers are available in different cooling capacities to suit various application needs, ranging from small control panels to large enclosures with significant heat loads. Please fill the Sizing Guide and send to us to recommend the perfect model for your panel/enclosure.

For more information contact us at below contact details or visit our website www.vivekengineers.net

Vivek Engineers #22, 1st Floor, 1st Cross,  Bilekahalli Indl. Area, Adj. IIMB Compound,  Bannerghatta Road, Bangalore - 560 076  Mob: 9740439220 Ph : 080 -  2648 1309, 4170 1145 Email: sales@vivekengineers.net           durga@vivekengineers.net           p.lochan@vivekengineers.net

🔧 Introducing the Air Amplifier by Exair USA 🔧

  The Air Amplifier from Exair USA is an innovative solution designed to efficiently utilize compressed air up to 17 bar pressure for various industrial applications. This high-performance tool is engineered to optimize your operations while ensuring reliability and minimal maintenance.

Key Features and Applications:

Vent Welding Smoke: Efficiently remove welding smoke from the work area, ensuring a safer and cleaner environment for workers.
Cool Hot Parts: Rapidly cool down hot components, enhancing safety and productivity in your processes.
Dry Wet Parts: Effectively dry wet surfaces, preparing them for the next stage of production.
Clean Machined Parts: Maintain the integrity of machined parts by removing debris and contaminants.
Distribute Heat: Evenly distribute heat in molds or ovens, ensuring uniform temperature control.
Ventilate Confined Areas: Provide fresh air to confined spaces, improving air quality and worker safety.
Dust Collection: Collect and manage dust efficiently, maintaining a clean and compliant workspace.
Exhaust Tank Fumes: Safely exhaust harmful fumes from tanks, protecting both workers and the environment.

Advantages:
Maintenance-Free: The Air Amplifier is designed with no moving parts, making it completely maintenance-free and ensuring long-term reliability. 🔩
Durable Construction: Made from either high-quality stainless steel or aluminum, it offers exceptional durability and resistance to harsh industrial environments. 🛠️
Efficient Operation: Harnessing the power of compressed air, it delivers efficient and cost-effective performance. ⚙️
Whether you need to cool, dry, clean, or ventilate, the Air Amplifier by Exair USA is your go-to solution for a variety of industrial applications. Its robust construction and maintenance-free design make it a valuable addition to any facility.
✨ Experience the Excellence of Air Amplification with Exair USA ✨

For more information contact us at below contact details or visit our website www.vivekengineers.net

Vivek Engineers #22, 1st Floor, 1st Cross,  Bilekahalli Indl. Area, Adj. IIMB Compound,  Bannerghatta Road, Bangalore - 560 076  Mob: 9740439220 Ph : 080 -  2648 1309, 4170 1145 Email: sales@vivekengineers.net           durga@vivekengineers.net           p.lochan@vivekengineers.net